Optimized system, box and bag for packing, shipping, storing and displaying produce

ABSTRACT

Produce boxes and bags for shipping produce, e.g., bananas, utilize ventilation structures that allow for ventilation therethrough. A method of assembling produce boxes provides for cutouts that serve as ventilation structures in the boxes. When the produce boxes are stacked such as on a shipping pallet, the ventilation structures allow for ventilation of through the stacked boxes. Produce may be packed in a bag, which is closed with a rip cord and inserted into a produce box. The rip cord may be accessed when the box is in a stack such as on a shipping pallet, such that the rip cord may be pulled thereby opening the bag, without removing the box from the stack.

PRIORITY

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/625,588, entitled “Optimized System, Box and Bag for Packing,Shipping, Storing and Displaying Produce,” filed Feb. 2, 2018, thedisclosure of which is incorporated herein by reference.

BACKGROUND

Perishable produce is often transported from where it is harvested tothe point of sale. For this reason, produce is packaged in boxes thatprotect the produce during shipment, while allowing for sufficientventilation of the produce to control air flow, moisture and/orripening, which may impact shelf life.

Bananas may be packed and shipped in corrugated boxes, such as box 50shown in FIG. 1A. For instance, box 50 comprises a base 51 and a lid 53positionable over base 51. Base 51 and/or lid 53 typically compriseventilation structures 57 (e.g., holes, cut-outs, etc.), on a side, top,and/or bottom surface of the base 51 and/or lid 53 to provideventilation. For added protection of the bananas 100, a flexible plasticbag 54 comprising a plurality of ventilation slits may be placed in thebase 51 of the box 50. Hands of bananas 100 are typically placed insideof the bag 54 in upper and lower rows. The lower rows may be coveredwith a paper tunnel pad to improve pack stability, and to protect thelower rows from damage, abrasion and/or scarring that could be caused bythe two upper rows. Once the bananas 100 are packed into the bag 54, theplastic bag 54 is gathered and folded so that the unfilled portion ofthe bag 54 overlaps the fruit. In the alternative, the open edges of thebag 54 are gathered together and closed with twine 55 above the fruit asshown in FIG. 1A. The box 50 is then closed by telescopically slidingthe lid 53 of the box over the base 51 of the box 50.

Once the box 50 is closed, it may be stacked onto a shipping pallet 52,along with other packed and closed boxes, as shown in FIG. 2. Referringto FIG. 1A, the lid 53 typically comprises flaps 59 extending along thelength of each sidewall of the box 50, which are folded over to form thetop surface of the lid 53. One or more boxes 50 can thereby be stackedon top of one another by placing the base 51 of a first box 50 onto thetop surface formed by flaps 59 of a second box 50.

Boxes 50 are then stacked onto the shipping pallet 52 such thatventilation structures 57 in the boxes 50 align with each other.Alignment of ventilation structures of boxes when they are on thepallet, allows air to circulate through all of the boxes on the pallet,which in turn allows for an optimal banana temperature (fortransportation, storage and ripening) to be reached, and provides foruniformity of the temperature across the pallet (thereby minimizingbanana color differentials across the pallet). To keep the boxes 50 inplace on the pallet 52 during shipment, plastic corner-boards and strapsmay be placed around the boxes 50 and the pallet 52 as is known in theart.

Once bananas (or other fruits) have been shipped to their destination,they may be ripened while on the pallets in a ripening room. Once thebananas are ripe, the straps and corner-boards may be removed from thepallet and the required number of boxes may be sent to the point ofpurchase. When the pallet arrives at a store, the plastic overwrap isopened and/or removed, to access the boxes. For example, FIG. 2 shows ashipping pallet 52 of prior art banana boxes 50 after the plasticoverwrap (not shown) has been removed.

To display bananas, a prior art banana box 50 may be removed from thepallet 52 and the lid 53 of the box 50 may be cut open, or in thealternative, the lid 53 can be removed and inverted and the base 51 ofthe box 50 can be telescopically slid into the lid 53. The plastic bag54 inside the box 50 may then be opened. The opened plastic bag 54 maybe draped over the sides of the box 50 to return the box 50 to theopened configuration, as shown in FIG. 1B, so the bananas 100 can beeasily removed from the box 50.

An exemplary display 1100 of bananas 100 in a store is shown in FIG. 3.As bananas 100 are sold, bananas are replenished on the display 1100throughout the course of the day. To make the re-stocking processeasier, opened boxes 50 may be stored at or near the display 1100, orunder the display 1100 as shown in FIG. 3. If there is not sufficientspace to store some or all of the opened boxes 50 near the display 1100,then some or all of the opened boxes 50 may be stored on the shippingpallet 52 until needed. To keep the stored bananas from ripeningprematurely and shortening their shelf-life, each opened box 50 isre-placed onto the shipping pallet 52 in a cross-stack as shown in FIG.4.

The steps of removing an overwrap from a pallet load of boxes, removingboxes from the pallet, opening the boxes and the plastic bags containedtherein to prepare the boxes, and, in some instances, cross-stacking theprepared boxes back onto the pallet is labor intensive and timeconsuming. Thus, there is a need for an improved banana box and plasticbag that allows for maintenance of favorable shipping and storageconditions, while providing for improved handling and storage at thepoint of purchase. The need is particularly felt for bananas, but alsoapplies to other produce, including other fruits and vegetables, whichrequire similar handling, and may also have varying requirements duringthe packing, shipping and storing processes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective exploded view of a prior art produce box.

FIG. 1B is a perspective view of the prior art produce box of FIG. 1A inan opened configuration.

FIG. 2 is a perspective view of a plurality of the prior art produceboxes of FIG. 1A stacked on a shipping pallet.

FIG. 3 is a perspective view of a display of bananas at a point ofpurchase and a stock of bananas under the display in the prior artproduce box of FIG. 1B.

FIG. 4 is a perspective view of the prior art produce box of FIG. 1Bcross-stacked back onto a pallet.

FIG. 5 is a top perspective view of a first exemplary produce box perthe present disclosure.

FIG. 6 is an exploded view of the produce box of FIG. 5.

FIG. 7 is a top plan view of an unassembled base of the produce box ofFIG. 5.

FIG. 8 is a top plan view of another unassembled base for use with theproduce box of FIG. 5.

FIG. 9 is a top plan view of an unassembled lid of the produce box ofFIG. 5.

FIG. 10 is a top perspective view of a plurality of the produce boxes ofFIG. 5 stacked on top of one another.

FIG. 11 is a bottom perspective view of the plurality of the produceboxes of FIG. 5 stacked on top of one another.

FIG. 12 is a top plan view of a tunnel pad for use with the produce boxof FIG. 5.

FIG. 13 is a top plan view of a bag for use with the produce box of FIG.5.

FIG. 14 is a top plan view of a ripcord for use with the bag of FIG. 13.

FIG. 15 is a front view of the ripcord of FIG. 14 being tied into a knotusing a first method.

FIG. 16 is a front view of the ripcord of FIG. 14 being tied into a knotusing a second method.

FIG. 17 is a front view of the ripcord of FIG. 14 tied into a knot.

FIG. 18 is a top perspective view of the produce box of FIG. 5 storing aclosed bag of bananas.

FIG. 19 is a top perspective view of a second exemplary produce box perthe present disclosure.

FIG. 20 is an exploded view of the produce box of FIG. 19.

FIG. 21 is a top plan view of an unassembled base of the produce box ofFIG. 19.

FIG. 22 is a top plan view of an unassembled lid of the produce box ofFIG. 19.

DETAILED DESCRIPTION

The present disclosure is directed to improved boxes, improved plasticbags, systems comprising them and methods of their use. As described infurther detail below, the boxes comprise a substantially rigid outer lidportion and a substantially rigid base portion. When in an assembledstate, the lid portion of the box telescopically slides over the baseportion of the box. The lid portion of the box comprises corner tabsthat are joined together to form platforms supported by the side wallsof the lid portion. The platforms provide a surface onto which otherboxes may be stacked, such as on a pallet. The platforms and tops of theside walls of the box define an opening in the lid portion, such thatproduce (e.g., bananas) inside the box are visible and/or accessiblethrough the opening, in contrast to the prior art box, which requiresremoval of the lid portion of the box to access the produce (e.g.,bananas) that are inside the box.

In accordance with the present disclosure, bananas may be packed into animproved bag that is draped over the sides of the base of the box duringthe packing process as described above. Once the bananas are packed intothe bag, it is closed using a ripcord that is tied in a knot around theopening in the bag. The improved bag comprises perforations as describedbelow, that allow the bag to easily be opened by pulling on the ripcord.One or more ends of the ripcord may extend through an opening (e.g., ahandle) of the box, thereby allowing the bag to be opened withoutopening the box.

The improved box and bag may provide the following advantages:

Like prior art produce boxes and bags, the improved box and bag protectbananas during shipment, while allowing for adequate ventilation throughthe box and bag, and throughout the stacked boxes on a pallet. At thepoint of purchase, and after the plastic overwrap has been cut openand/or removed from the palletized boxes, the bags in the boxes may beopened by pulling the ripcords extending through an opening (e.g., thehandle) of the box. Thus, the improved box and bag eliminate the need toremove each box from the pallet and/or to open the box, prior to openingthe bag. Since there is adequate ventilation throughout the ventilationstructures of the improved boxes when they are stacked boxes on apallet, there is no need to remove the boxes from the pallet, open them,open the bags and then cross-stack the boxes back onto the pallet forstorage. But rather, to store bananas in improved boxes on a pallet atthe point of purchase, only two steps are needed, removal or opening ofthe plastic overwrap from the pallet and pulling the ripcord to openeach of the improved bags, while leaving the improved boxes closed andstacked on the pallet.

As described below, some exemplary boxes comprise an opening in its topportion that is large enough to permit removal of the bananas from thebox without opening the box, such as by cutting it open, or removing thelid. Bananas packed inside these exemplary boxes may be readily removedfrom the box by simply pulling the ripcord to open the improved bag.Thus, these exemplary boxes can be moved from a pallet nearer to thepoint of purchase display and bananas readily removed therefrom, withoutany further processing of the box, including opening the box.

Reference will now be made in detail to the aspects of the disclosure,examples of which are illustrated in the accompanying drawings, whereinlike numerals indicate the same elements throughout the views.

Referencing FIGS. 5-6, an exemplary box 10 for produce, particularlybananas, is provided. Produce box 10 comprises a base 12 and a lid 32that may be positioned over base 12. Each of these components will bediscussed in more detail below.

FIG. 7 shows base 12 of produce box 10 in an unassembled state. In theunassembled state, the base 12 comprises a first side panel 11, a frontpanel 13, a second side panel 15 and a rear panel 17 alignedlongitudinally with each other. Each panel 11, 13, 15, 17 comprises arespective flap 21, 23, 25, 27 extending outwardly from each panel 11,13, 15, 17. In the illustrated example, the flaps 21, 23, 25, 27 eachextend from the bottom edge of each panel 11, 13, 15, 17 such that eachflap 21, 23, 25, 27 is longitudinally aligned with each other. A tab 29is further positioned adjacent to the first side panel 11. In theillustrated example, a score line 22 is provided between each panel 11,13, 15, 17, flap 21, 23, 25, 27, and tab 29 to allow for easier assemblyof base 12.

To assemble base 12, as shown in FIG. 6, the panels 11, 13, 15, 17 arefolded along the score lines 22 such that the side panels 11, 15 aresubstantially parallel with each other and the front and rear panels 13,17 are substantially parallel with each other. Tab 29 may be foldedinwardly and positioned against the interior surface of rear panel 17.In some versions, tab 29 is adhered to the rear panel 17 to maintain thebase 12 in an assembled configuration. Panels 11, 13, 15, 17 therebyform an opening 24 through the top surface of the base 12. The flaps 21,23, 25, 27 are then folded inward and secured (e.g., glued) to oneanother in order to form a bottom surface of the base 12. As can be seenin FIG. 11, when exemplary base 12 is assembled, flaps 21, 23, 25, 27define an opening 26 in the bottom surface of the base 12, which aids inventilation of the box 10 taken alone or stacked on a pallet with otherboxes. Base 12 may be folded and glued at a packing station in aManufacturing Join at Box Plant.

At least one ventilation aperture 16 is located in the flaps 21, 23, 25,27 and/or on the panels 11, 13, 15, 17 of the base 12, and/or at leastone ventilation cutout 19 is located on the panels 11, 13, 15, 17. Forinstance, as shown in FIGS. 6 and 7, each of the side panels 11, 15comprise a ventilation cutout 19 extending inwardly from a top edge ofthe side panels 11, 15. Cutouts 19 have a generally rectangular shapewith or without rounded corners. Other suitable shapes can be selectedfrom square, triangular or trapezoidal. Such cutouts may extend alongfrom about 30% to about 55% or from about 35% to about 50% of the lengthof each panel 11, 15. Some exemplary cutouts may extend along about 35%or about 50% of the length of each panel 11, 15. These cutouts 19 mayallow air to flow through the cutouts 19 and laterally across a topportion of the box 10 to ventilate the box 10 when a plurality of boxes10 are assembled and stacked on top of each other. While the cutouts 19are shown on each of the side panels 11, 15, cutouts 19 may bepositioned on any one or more of the panels 11, 13, 15, 17 of producebox 10. In the illustrated example, base 12 further comprises one ormore apertures 16 on the front panel 13, rear panel 17, and flaps 21,25. This may provide for further ventilation of box 10. Handholds (i.e.,“handles”) 18 may also be provided for additional ventilation, and/orfor ease of transporting the box 10. Still other suitable ventilationconfigurations will be apparent to one with ordinary skill in the art inview of the teachings herein.

For instance, FIG. 8 is an unassembled view of another exemplary base212 that is similar to base 12, except that base 212 comprises largerventilation apertures 216 and handholds 218.

FIG. 9 shows the lid 32 of the produce box 10 in an unassembled state.In the unassembled state, the lid 32 comprises a first side panel 31, afront panel 33, a second side panel 35 and a rear panel 37 alignedlongitudinally with each other. Each panel 31, 33, 35, 37 comprises atab 34 extending outwardly from each corner of the top edge of eachpanel 31, 33, 35, 37. While the illustrated example shows each tab 34comprising a square portion with an arcuate portion extending from aninterior top edge of the square portion of the flap 34 inwardly to thetop edge of the panel 31, 33, 35, 37, other suitable shapes can be used.Each square portion of the tab 34 may have a width of about 2.5 inchesand a length of about 2.5 inches, but other suitable dimensions can beused. For instance, each tab 34 may extend up to about 25% of the lengthof each panel 31, 33, 35, 37. A tab 39 is further positioned adjacent tothe first side panel 31. In the illustrated example, a score line 40 isprovided between each panel 31, 33, 35, 37 and tabs 34, 39 to allow foreasier assembly of lid 32.

To assemble lid 32, as shown in FIG. 6, the panels 31, 33, 35, 37 arefolded along the score lines 40 such that the side panels 31, 35 aresubstantially parallel with each other and the front and rear panels 33,37 are substantially parallel with each other. Tab 39 may be foldedinwardly and positioned against the interior surface of rear panel 37.In some versions, tab 39 is adhered to the rear panel 37 to maintain thelid 32 in an assembled configuration. Panels 31, 33, 35, 37 thereby forman opening 44 through the bottom surface of the lid 32. The tabs 34 arethen folded inward and secured (e.g., glued) to one another in order toform a corner 46 on each corner of the lid 32 to form a top surface ofthe lid 32. As can be seen in FIG. 6, when exemplary lid 32 isassembled, corners 46 define an opening 44 in the top surface of the lid32, which aids in ventilation of the box 10 taken alone or stacked on apallet with other boxes. In the illustrated example, the opening 44comprises about 90% of a top surface of the lid 32, but other suitableconfigurations can be used. Lid 32 may be folded and glued at a packingstation in a Manufacturing Join at Box Plant.

At least one ventilation aperture 36 is located in the panels 31, 33,35, 37 of the lid 32, and/or at least one ventilation cutout 39 islocated on the panels 31, 33, 35, 37. For instance, as shown in FIGS. 6and 7, each of the side panels 31, 35 comprise a ventilation cutout 39extending inwardly from a top edge of the side panels 31, 35. Cutouts 39have a generally rectangular shape with or without rounded corners.Other suitable shapes can be selected from square, triangular ortrapezoidal. Such cutouts may extend along from about 30% to about 55%or from about 35% to about 50% of the length of each panel 31, 35. Someexemplary cutouts may extend along about 35% or about 50% of the lengthof each panel 31, 35. These cutouts 39 may allow air to flow through thecutouts 39 and laterally across a top portion of the box 10 to ventilatethe box 10 when a plurality of boxes 10 are assembled and stacked on topof each other. While the cutouts 39 are shown on each of the side panels31, 35, cutouts 39 may be positioned on any one or more of the panels31, 33, 35, 37 of produce box 10. In the illustrated example, lid 32further comprises one or more apertures 36 on the front panel 33 andrear panel 37. This may provide for further ventilation of box 10.Handholds (i.e., “handles”) 38 may also be provided for additionalventilation, and/or for ease of transporting the box 10. Still othersuitable ventilation configurations will be apparent to one withordinary skill in the art in view of the teachings herein.

In some examples, lid 32 and base 12 are of approximately equal score toscore depth as shown in FIG. 5. To assemble box 10, lid 32telescopically slides over base 12. Accordingly, the first side panel 31of the lid 32 is positioned over the first side panel 11 of the base 12,the front panel 33 of the lid 32 is positioned over the front panel 13of the base 12, the second side panel 35 of the lid 32 is positionedover the second side panel 15 of the base 12, and the rear panel 37 ofthe lid 32 is positioned over the rear panel 17 of the base 12. Thisaligns the top opening 44 of the lid 32 with the top opening 24 of thebase 12 and the bottom opening 42 of the lid 32 with the bottom opening26 of the base 12. Ventilation cutouts 19, 39, apertures 16, 36, andhandholds 18, 38 of the base 12 and lid 32 are also aligned with eachother to provide ventilation through the box 10.

In the assembled state, box 10 may be about 19 and ⅞ inches long byabout 15 9/16 inches wide by about 9 and ¾ inches high, within amanufacturing tolerance of about ±0.1 inches, or about ±0.06 inches.Still other suitable dimensions can be used that will be apparent to onewith ordinary skill in the art in view of the teachings herein. Forinstance, exemplary boxes may have defined dimensions such that theboxes may fit snugly on a pallet without overhanging the edges of thepallet, thereby protecting the fruit from damage during shipping. Theboxes 10 are generally made from corrugated cardboard, but can be madefrom any material typically used for making shipping boxes. The choiceof material is governed by such factors as cost and strength/durability.

Once assembled, the boxes 10 may be stacked on top of each other in astacked configuration (FIGS. 10 and 11) such that a bottom surface of abase 12 is positioned on a top surface of a lid 32 of a box 10. In theillustrated example, the top surface of the lid 32 is defined by the topsurface of the corners 46 formed by the folded flaps 34 of the lid 32.The top surface of the corners 46 may thereby provide a surface area toreceive the bottom portion of another box 10 such that one or moreadditional boxes may be stacked, such as on a pallet. Accordingly, thecorners 46 may be formed such that the corners 46 are sufficientlystrong enough to support the weight of another box 10 stacked on top ofthe corners 46 of a lid 32 such that the corners 46 maintain their shapein a stacked configuration without deforming the box 10. Produce, e.g.,bananas, may be seen through and/or removed from an assembled box 10through the opening 44 in the lid 32.

The boxes 10 of the present disclosure include an improved ventilationsystem.

Referencing FIGS. 10 and 11, boxes 10 are structured so that air cancirculate through all of the boxes 10 when they are stacked on top ofeach other, such as on a shipping pallet. This can allow for the boxesto be stacked on a pallet, e.g., in 8 layers of 6 boxes for a regularshipping pallet, or in 4 layers of 6 boxes for a “half-pallet,” whileallowing for adequate ventilation through the palletized boxes.Ventilation and air flow serve two important functions with regard toboxes 10 stacked on a shipping pallet: (1) they allow for efficient airflow which may provide an optimal banana temperature (fortransportation, storage and ripening) to be reached; and (2) theyprovide for uniformity of that temperature across the pallet (therebyminimizing banana color differentials across the pallet). Ventilationand air flow are usually achieved by placing apertures and/or cutouts inboxes which are not blocked (and allow air flow) when individual boxesare stacked on top of each other and adjacent to one another. Examplesof such banana boxes ventilation systems, which may be of use in theimproved systems of the present disclosure, are described in PCTPublished Patent Application WO 2004/045972, published Jun. 3, 2004; andU.S. Published Patent Application 2003/0198714, published Oct. 23, 2003;each of which are incorporated by reference herein.

Produce, particularly bananas, may be packed into the improved boxes inany suitable fashion. For example, hands of bananas may be packed infour rows, which in turn comprises two lower and two upper rows. The twolower rows may be covered with a paper tunnel pad to improve packstability, and to protect the lower rows from damage, abrasion and/orscarring that could be caused by the two upper rows. Referencing FIG.12, an exemplary tunnel pad 60 of use is shown. Exemplary tunnel padswhich may be of use in the improved boxes are described in PCT PublishedPatent Application WO 2004/045972, which is incorporated herein byreference.

When perishable produce, such as bananas, is shipped in a box, aflexible plastic inner wrap or bag is typically employed to protect theproduce and/or and to control fruit dehydration. This inner wrap may bea bag made of plastic with a plurality of ventilation slits providedabout the surface of the bag. The bag is typically placed in the baseportion of a box, and the open edges of the bag are draped over itssidewalls. In this fashion, fruit, such as bananas, placed inside thebag, such as by being layered therein. Once fruit is packed into thebag, the plastic bag may be gathered and folded so that the unfilledportion of the bag overlaps the fruit. In the alternative, the openedges of the bag 54 may be gathered together and closed with twine 55above the fruit (for example, as shown in relation to the prior art boxand plastic bag 54 in FIG. 1A).

Improved plastic bag 70 according to the present disclosure is shown inFIG. 13. As can be seen in FIG. 13, improved plastic bag 70 comprises anopen top end 76, a closed bottom end 78, and a plurality of perforations71 through the sidewalls of the bag 70. Perforations 71 aid inventilation of produce contained within bag 70 which helps to controlhumidity, temperature and color of the fruit. A neck 72 is provided atthe top portion of the bag 70 adjacent to open top end 76, defined aboveperforation line 74. Perforation line 74 acts as a line of weakness sothat the bag 70 may be easily opened by pulling a ripcord 80 that hasbeen tied around neck 72 of bag 70 as described below. When the ripcord80 is pulled the neck 72, or top portion of the bag 70, is easily tornand/or removed. This feature of improved bag 70 may be particularlyadvantageous since it allows the box 10 to be easily opened at the pointof purchase without being removed from a stack of boxes. Improved bag 70may be filled with bananas prior to box 10 being assembled as shown inFIG. 5.

An exemplary ripcord 80 is shown in FIG. 14 having a first end 82 and asecond end 84. Ripcord 80 may be made from any suitable material so longas it has the strength to secure closure of plastic bag 70 until suchtime as it is opened at the point of purchase. Ripcord 80 may be tiedabout neck 72 of bag 70 to form a knot 86, as shown in FIG. 17, aboutneck 72. Knot 86 may be formed in any suitable fashion, such as themethods shown in FIGS. 15 and 16. FIG. 15 shows knot 86 being formed bylooping the first end 82 of ripcord 80 behind the second end 84 andthreading the first end 82 through the loop. FIG. 16 shows knot 86 beingformed by looping the first end 82 of ripcord 80 in front of the secondend 84 and threading the first end 82 through the loop. Still othersuitable methods to form knot 86 will be apparent to one with ordinaryskill in the art in view of the teachings herein.

Referring to FIG. 18, once plastic bag 70 is filled with bananas it issecured in a closed position with ripcord 80. For instance, ripcord 80is tied around the neck 72 of plastic bag 70 in a knot 86 that securesplastic bag 70 in a closed position. An end 82 of ripcord 80 is passedthrough an opening in the box 10 (e.g., handle 18) so that it mayreadily be accessed even when box 10 is stacked on a pallet and/or hasanother box stacked on its top. The end 82 of ripcord 80 may then bepulled from the exterior of the box 10 to open the bag 70. The force ofpulling ripcord 80 results in tearing along perforation line 74 suchthat a top portion of the improved bag 70 is removed, thereby openingthe bag 70. Accordingly, the bag 70 can be opened without accessing theinterior portion of the box 10 such that the bag 70 may be opened whilethe box 10 is in a stacked configuration.

FIGS. 19-23 show another example of a produce box 110 that is similar toproduce box 10, except that produce box 110 comprises ventilationcutouts in the flaps of the lid. Similar to produce box 10, produce box110 comprises a base 112 and a lid 132 that may be positioned over base112. Each of these components will be discussed in more detail below.

FIG. 21 shows base 112 of produce box 110 in an unassembled state. Inthe unassembled state, the base 112 comprises a first side panel 111, afront panel 113, a second side panel 115 and a rear panel 117 alignedlongitudinally with each other. Each panel 111, 113, 115, 117 comprisesa respective flap 121, 123, 125, 127 extending outwardly from each panel111, 113, 115, 117. In the illustrated example, the flaps 121, 123, 125,127 each extend from the bottom edge of each panel 111, 113, 115, 117such that each flap 121, 123, 125, 127 is longitudinally aligned witheach other. A tab 129 is further positioned adjacent to the first sidepanel 129. In the illustrated example, a score line 122 is providedbetween each panel 111, 113, 115, 117, flap 121, 123, 125, 127, and tab129 to allow for easier assembly of base 112.

To assemble base 112, as shown in FIG. 20, the panels 111, 113, 115, 117are folded along the score lines 122 such that the side panels 111, 115are substantially parallel with each other and the front and rear panels113, 117 are substantially parallel with each other. Tab 129 may befolded inwardly and positioned against the interior surface of rearpanel 117. In some versions, tab 129 is adhered to the rear panel 117 tomaintain the base 112 in an assembled configuration. Panels 111, 113,115, 117 thereby form an opening 124 through the top surface of the base112. The flaps 121, 123, 125, 127 are then folded inward and secured(e.g., glued) to one another in order to form a bottom surface of thebase 112. As can be seen in FIG. 20, when exemplary base 112 isassembled, flaps 121, 123, 125, 127 define an opening 126 in the bottomsurface of the base 112, which aids in ventilation of the box 110 takenalone or stacked on a pallet with other boxes. Base 112 may be foldedand glued at a packing station in a Manufacturing Join at Box Plant.

At least one ventilation aperture 116 is located in the flaps 121, 123,125, 127 and/or on the panels 111, 113, 115, 117 of the base 112, and/orat least one ventilation cutout 119 is located on the panels 111, 113,115, 117. For instance, as shown in FIGS. 20 and 21, each of the sidepanels 111, 115 comprise a ventilation cutout 119 extending inwardlyfrom a top edge of the side panels 111, 115. Cutouts 119 have agenerally rectangular shape with or without rounded corners. Othersuitable shapes can be selected from square, triangular or trapezoidal.Such cutouts may extend along from about 30% to about 55% or from about35% to about 50% of the length of each panel 111, 115. Some exemplarycutouts may extend along about 35% or about 50% of the length of eachpanel 111, 115. These cutouts 119 may allow air to flow through thecutouts 119 and laterally across a top portion of the box 110 toventilate the box 110 when a plurality of boxes 110 are assembled andstacked on top of each other. While the cutouts 119 are shown on each ofthe side panels 111, 115, cutouts 119 may be positioned on any one ormore of the panels 111, 113, 115, 117 of produce box 110. In theillustrated example, base 112 further comprises one or more apertures116 on the front panel 113, rear panel 117, and flaps 121, 125. This mayprovide for further ventilation of box 110. Handholds (i.e., “handles”)118 may also be provided for additional ventilation, and/or for ease oftransporting the box 110. Still other suitable ventilationconfigurations will be apparent to one with ordinary skill in the art inview of the teachings herein.

Some exemplary bases 112 may be reinforced so that they may be stackedin bottom layer(s) of a pallet without being crushed by the weight offurther boxes 110 that are subsequently stacked thereon. A reinforcedbase 112 may comprise paper having a relatively higher grammage thanpaper that is used to form the bases 112 of boxes 110 stacked in higherlayer(s) of boxes 110 on a pallet.

FIG. 22 shows the lid 132 of the produce box 110 in an unassembledstate. In the unassembled state, the lid 132 comprises a first sidepanel 131, a front panel 133, a second side panel 135 and a rear panel137 aligned longitudinally with each other. Each panel 131, 133, 135,137 comprises a respective flap 141, 143, 145, 147 extending outwardlyfrom each panel 131, 133, 135, 137. In the illustrated example, theflaps 141, 143, 145, 147 each extend from the top edge of each panel131, 133, 135, 137 such that each flap 141, 143, 145, 147 islongitudinally aligned with each other. A tab 139 is further positionedadjacent to the first side panel 131. In the illustrated example, ascored line 140 is provided between each panel 131, 133, 135, 137, flap141, 143, 145, 147, and tab 139 to allow for easier assembly of lid 132.

To assemble lid 132, as shown in FIG. 20, the panels 131, 133, 135, 137are folded along the score lines 140 such that the side panels 131, 135are substantially parallel with each other and the front and rear panels133, 137 are substantially parallel with each other. Tab 139 may befolded inwardly and positioned against the interior surface of rearpanel 137. In some versions, tab 139 is adhered to the rear panel 137 tomaintain the lid 312 in an assembled configuration. Panels 131, 133,135, 137 thereby form an opening through the bottom surface of the lid132. The flaps 141, 143, 145, 147 are then folded inward and secured(e.g., glued) to one another in order to form a top surface of the lid132. As can be seen in FIG. 20, when exemplary lid 132 is assembled,flaps 141, 143, 145, 147 define an opening 144 in the top surface of thelid 132, which aids in ventilation of the box 110 taken alone or stackedon a pallet with other boxes. Lid 132 may be folded and glued at apacking station in a Manufacturing Join at Box Plant.

At least one ventilation aperture 136 is located in the panels 131, 133,135, 137 of the lid 132, and/or at least one ventilation cutout 139 islocated on the panels 131, 133, 135, 137. For instance, as shown inFIGS. 20 and 22, each of the side panels 131, 135 comprise a ventilationcutout 139 extending inwardly from a top edge of the side panels 131,135. Cutouts 139 have a generally rectangular shape with or withoutrounded corners. Other suitable shapes can be selected from square,triangular or trapezoidal. Such cutouts may extend along from about 30%to about 55% or from about 35% to about 50% of the length of each panel131, 135. Some exemplary cutouts may extend along about 35% or about 50%of the length of each panel 131, 135. These cutouts 139 may allow air toflow through the cutouts 139 and laterally across a top portion of thebox 110 to ventilate the box 110 when a plurality of boxes 110 areassembled and stacked on top of each other. Cutouts 139 are alsoprovided on the edge of each flap 141, 145 adjacent to the panels 131,135 to align with the cutouts 139 on the panels 131, 135. This may allowfor increased ventilation at the top portion of the box 110. While thecutouts 139 are shown on each of the side panels 131, 135, and flaps141, 145, cutouts 139 may be positioned on any one or more of the panels131, 133, 135, 137 and/or flaps 141, 143, 145, 147 of produce box 110.

In the illustrated example, lid 132 further comprises one or moreapertures 136 on the front panel 133 and rear panel 137. This mayprovide for further ventilation of box 110. Handholds (i.e., “handles”)138 may also be provided for additional ventilation, and/or for ease oftransporting the box 110. Still other suitable ventilationconfigurations will be apparent to one with ordinary skill in the art inview of the teachings herein.

In some examples, lid 132 and base 112 are of approximately equal scoreto score depth as shown in FIG. 19. To assemble box 110, lid 132telescopically slides over base 112. Accordingly, the first side panel131 of the lid 132 is positioned over the first side panel 111 of thebase 112, the front panel 133 of the lid 132 is positioned over thefront panel 113 of the base 112, the second side panel 135 of the lid132 is positioned over the second side panel 115 of the base 112, andthe rear panel 137 of the lid 132 is positioned over the rear panel 117of the base 112. This aligns the top opening 144 of the lid 132 with thetop opening 124 of the base 112 and the bottom opening 142 of the lid132 with the bottom opening 126 of the base 112. Ventilation cutouts119, 139, apertures 116, 136, and handholds 118, 138 of the base 112 andlid 132 are thereby aligned with each other to provide ventilationthrough the box 110.

Examples

A first exemplary box for storing produce comprising:

-   -   a bottom surface;    -   a pair of opposing side panels;    -   a pair of opposing end panels positioned between the pair of        opposing side panels such that each end panel is adjacent to        each side panel; and    -   a top surface comprising corners extending between an end        portion of each side panel and an end portion of each adjacent        end panel, wherein the corners define an opening extending        between the corners along the top surface, wherein the corners        provide a surface area for receiving the bottom surface of        another box in a stacked configuration.

A second exemplary box according to the first exemplary box, furthercomprising one or more apertures in at least one of the end panels.

A third exemplary box according to either one of the first or secondexemplary boxes, further comprising a flexible bag disposed inside thebox, wherein the flexible bag comprises a neck which can be opened.

A fourth exemplary box according to the third exemplary box, wherein theflexible bag comprises a perforation line disposed along the neck of thebag.

A fifth exemplary box according to either one of the third and fourthexemplary boxes, further comprising a ripcord that is configured tosecure the neck in a closed position.

A sixth exemplary box according to the fifth exemplary box, wherein theripcord is configured to open the bag along the perforation line whenthe ripcord is pulled.

A seventh exemplary box according to either one of the fifth or sixthexemplary boxes, wherein an end of the ripcord is disposed through anaperture of the box.

An eighth exemplary box according to the seventh exemplary box whereinthe aperture is a handhold.

A ninth exemplary box according to any one of the first through eighthexemplary boxes, wherein the produce is bananas.

A first exemplary method for storing and shipping produce utilizing abox, a flexible bag, and a ripcord, wherein the box comprises a baseportion a top portion, such that when the box is in a closedconfiguration, the top portion is disposed telescopically over the baseportion such that one or more ventilation structures in the base portionand the top portion are aligned, wherein the flexible bag comprises aneck through which produce may be inserted, wherein the neck comprises aperforation line, and the ripcord is configured to releasably secure theneck in a closed position, the method comprising:

-   -   (a) placing the flexible bag in the base portion;    -   (b) placing produce into the flexible bag through the neck;    -   (c) securing the neck of the flexible bag in a closed position        with the ripcord;    -   (d) placing the top portion of the box over the base portion of        the box so that the box is in the closed configuration; and    -   (e) passing an end of the ripcord through at least one of the        ventilation structures in the box in the closed configuration.

A second exemplary method according to the first exemplary method,further comprising opening the bag by pulling the ripcord and tearingthe bag along the perforation line.

A third exemplary method according to the second exemplary method,further comprising opening the bag without removing the top portion fromthe base portion of the box.

A fifth exemplary method according any one of the first through thirdexemplary methods, wherein the ventilation structure is a handhold.

A sixth exemplary method according to any one of the first through fifthexemplary methods, wherein the produce is bananas.

An exemplary system for packing, storing, shipping and/or displayingproduce comprising:

-   -   (a) a box comprising:        -   (1) a bottom surface;        -   (2) a pair of opposing side panels;        -   (3) a pair of opposing end panels positioned between the            pair of opposing side panels such that each end panel is            adjacent to each side panel; and        -   (4) a top surface comprising corners extending between an            end portion of each side panel and an end portion of each            adjacent end panel, wherein the corners define an opening            extending between the corners along the top surface, wherein            the corners provide a surface area for receiving the bottom            surface of another box in a stacked configuration;    -   (b) a flexible bag comprising:        -   (1) a neck which can be opened; and        -   (2) a perforation line disposed on the neck;    -   wherein the bag is configured to be opened by applying force to        the perforation line; and (c) a ripcord that is configured to:        -   (1) secure the bag in a closed position at the neck; and        -   (2) open the bag along the perforation line when the ripcord            is pulled.

What is claimed is:
 1. A box for storing produce comprising: a basecomprising a front panel, a rear panel, and a pair of opposing sidepanels, wherein the front, rear, and opposing side panels define a topopening, wherein the base comprises at least one cutout extendinginwardly from a top edge of a select one or more of the front, rear, andopposing side panels adjacent to the top opening, wherein the at leastone cutout has a substantially rectangular shape and wherein the cutoutextends along about 30% to about 55% of a length of the top edge of theselect one or more of the front, rear, and opposing side panels; and alid comprising a front panel, a rear panel, and a pair of opposing sidepanels, wherein the front, rear, and opposing side panels define a topopening, wherein the lid comprises at least one cutout extendinginwardly from a top edge of a select one or more of the front, rear, andopposing side panels adjacent to the top opening; wherein the lid ispositionable about the base such that the at least one cutout of the lidis aligned with the at least one cutout of the base.
 2. The box of claim1, wherein the base further comprises a flap extending from a bottomedge each of the front, rear, and opposing side panels, wherein theflaps form a bottom surface of the box.
 3. The box of claim 2, whereinthe flaps define a bottom opening through the bottom surface of the box.4. The box of claim 1, wherein the base further comprises at least oneaperture through a select one or more of the front, rear, and opposingside panels.
 5. The box of claim 1, wherein the base further comprisesat least one handhold through a select one or more of the front, rear,and opposing side panels.
 6. The box of claim 1, wherein the lid furthercomprises a tab extending from each end of a top edge of each of thefront, rear, and opposing side panels, wherein the tabs form a topsurface of the box.
 7. The box of claim 1, wherein the lid furthercomprises a flap extending from a bottom edge each of the front, rear,and opposing side panels, wherein the flaps form a top surface of thebox.
 8. The box of claim 7, wherein the lid comprises at least onecutout extending inwardly from an edge of a select one or more of theflaps.
 9. The box of claim 1, wherein the lid further comprises at leastone aperture through a select one or more of the front, rear, andopposing side panels.
 10. The box of claim 1, wherein the at least onecutout extends along about 35% of the length of the top edge of theselect one or more of the front, rear, and opposing side panels.
 11. Thebox of claim 1, wherein the at least one cutout extends along about 50%of the length of the top edge of the select one or more of the front,rear, and opposing side panels.
 12. The box of claim 1, comprising aflexible bag disposed inside the box, wherein the flexible bag comprisesa neck at a top portion of the flexible bag, wherein the flexible bagcomprises a top opening above the neck.
 13. The box of claim 12, whereinthe flexible bag comprises a perforation line disposed below the neck ofthe bag.
 14. The box of claim 13, further comprising a ripcordpositionable about the neck such that the ripcord is configured tosecure the neck in a closed position.
 15. The box of claim 14, whereinthe ripcord is configured to open the bag along the perforation linewhen the ripcord is pulled.
 16. The box of claim 14, wherein an end ofthe ripcord is disposed through an aperture of the box.
 17. A box forstoring produce comprising: a base comprising a front panel, a rearpanel, and a pair of opposing side panels, wherein the front, rear, andopposing side panels, wherein the base comprises at least one opening ona select one or more of the front, rear, and opposing side panels; a lidcomprising a front panel, a rear panel, and a pair of opposing sidepanels, wherein the front, rear, and opposing side panels, wherein thelid comprises at least one opening on a select one or more of the front,rear, and opposing side panels, wherein the lid is positionable on thebase such that the at least one opening of the lid is aligned with theat least one opening of the base; a bag disposed within the base,wherein the bag comprises a neck at a top portion of the bag, whereinthe bag comprises a top opening above the neck, wherein the bagcomprises a perforation line disposed below the neck of the bag; and aripcord positionable about the neck of the bag such that the ripcord isconfigured to secure the neck in a closed position, wherein the ripcordis configured to open the bag along the perforation line when theripcord is pulled, wherein an end of the ripcord is disposed through theat least one opening of the base and the lid.
 18. A method of assemblinga box for storing produce, wherein the box comprises a base comprising afront panel, a rear panel, and a pair of opposing side panels, whereinthe front, rear, and opposing side panels define a top opening, whereinthe base comprises at least one cutout extending inwardly from a topedge of a select one or more of the front, rear, and opposing sidepanels adjacent to the top opening, and a lid comprising a front panel,a rear panel, and a pair of opposing side panels, wherein the front,rear, and opposing side panels define a top opening, wherein the lidcomprises at least one cutout extending inwardly from a top edge of aselect one or more of the front, rear, and opposing side panels adjacentto the top opening, the method comprising the steps of: assembling thebox by positioning the lid on the base such that the at least one cutoutof the lid is aligned with the at least one cutout of the base; andstacking the assembled box on top of another assembled box such that thecutouts of the lid and the base are still exposed.
 19. The method ofclaim 18 further comprising: positioning a bag within the box, whereinthe bag comprises a neck at a top portion of the bag, wherein the bagcomprises a top opening above the neck, wherein the bag comprises aperforation line disposed below the neck of the bag; tying a ripcordabout the neck of the bag to secure the neck in a closed position; andthreading an end of the ripcord through the exposed cutouts of the box.20. The method of claim 19 further comprising pulling the end of theripcord to tear the bag open about the perforation line.